1.3.4 - Safety Practical

Objective: Make one part, in front of a mentor, without skipping a safety step. The member is asked to make the part on the drawing as the assignment.

Danger

A mentor is in the room for the whole practical. One student or a small group. You do not start a machine until that mentor says the setup is ready. Gloves stay off the saw, the sander, and the drill.

Glasses on. Hair tied back. Closed-toe shoes. Cleanup should not be skipped and is part of our Safety Plan.

🛠️ Approved Fabrication Tools

• Sharpie: For marking layout hole locations on part
• Measurement Tools: Calipers (for hole precision) and Tape Measure (for length).
• Milwaukee M12 Fuel Portable Bandsaw For stock cutting (1x2 tube).
• Horizontal Bandsaw For cutting of stock for straightest cuts. (1X2 tube).
• Milwaukee Cordless Drill: For all hole drilling and fastener driving.
• Standard Drill Bit Set: For creating pilot and clearance holes.
• Deburring Tools: Countersinks, or handheld swivel deburring tool.

The drawing

Cut length, hole size, and hole location come from this sheet. Do not guess.

Stock

Choose the correct stock: 1” × 2” tube, 1/8” wall.

Before you start

Say the length and both holes back to the mentor, be able to read the drawing.

Pass

Mentor signs the sheet when complete. Bench and machines are left the way you found them.

Do this in order

1. Read the task. Say the cut length and both hole sizes and locations before you touch stock.

2. Pick a space. Clear bench.

3. Get the tools. Marker, caliper, the saw you were assigned, drill, both bits, and a vise or clamp.

4. Get the material. The tube on the drawing, not a leftover that is close.

5. Mark the cut. Measure from a clean end. Mark the waste side so the 2.00 length is still there after the kerf.

6. Cut. Mentor checks the setup. Cordless saw with the stock in a vise, or the horizontal bandsaw with the stock clamped and the guard in place.

7. Stop the blade. Wait until it is still before you reach in.

8. Sand the edges. Sander off when not using, don’t walk away from a spinning machine. Deburr the cut. No gloves.

9. Mark the holes. Measure from the edges you just cut. Center punch the 3/8 and the 1/4 hole in the right location.

10. Drill. Clamp the part in vise. Bit matches the callout. Mentor checks the clamp and the bit. Stop the chuck before you move the part. Then the other hole.

11. Clean up. Tools back. Scrap in the bin. Bench brushed. Floor clear. Battery on charger if it needs it.

Rubric

A mentor to review.

Step	Pass	Not a pass
Brief	States length and both holes before starting	Starts from memory
PPE	Glasses, shoes, hair, no gloves on rotating tools	Fixes it only after being told twice
Setup	Stock and bits match the drawing; bench is clear	Wrong stock, wrong bit, or a cord across the walk
Mark and cut	Mark is on the waste side; saw stops before hands enter	Cuts short, holds stock by hand, or reaches in early
Edges	Cut edge deburred; part is safe to hand over	Sharp edge left on the cut
Holes	Both sizes and locations match; part was clamped	Handheld part, wrong bit, or hole in the wrong face
Cleanup	Tools, scrap, and floor done before the grade	Leaves the bench for someone else

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